Warp knitted pile fabric involving orientation by modifying warp



June 25, 1963 Filed Feb. 26. 1960 R. s. M cAFFRAY, JR 3,094,857 WARP KNITTED FILE FABRIC INVOLVING 12 Sheets-Sheet l INVENTOR June 25, 1963 5, MaGCAFFRAY, JR 3,094,857

WARP KNITTED PILE FABRIC INVOLVING ORIENTATION BY MODIFYING WARP l2 Sheets-Sheet 2 Filed Feb. 26, 1960 INVENTOR June 25, 1963 s, MaccAFFRAY, JR 3,094,857

WARP KNITTED FILE FABRIC INVOLVING ORIENTATION BY MODIFYING WARP Filed Feb. 26, 1960 12 Sheets-Sheet 3 INVENTOR June 25, 1963 R. s. M CAFFRAY, JR 3,094,857

WARP KNITTED PILE FABRIC INVOLVING ORIENTATION BY MODIFYING WARP Filed Feb. 26, 1960 12 Sheets-Sheet 4 INVENTOR June 25, 1963 5. MaccAFFRAY, JR 3,094,857

WARP KNITTED FILE FABRIC INVOLVING ORIENTATION BY MODIFYING WARP l2 Sheets-Sheet 5 Filed Feb. 26, 1960 June 25, 1963 R. s. M cAFFRAY, JR 3,094,857

WARP KNITTED PILE FABRIC INVOLVING ORIENTATION BY MODIFYING WARP Filed Feb. 26, 1960 12 Sheets-Sheet 6 INVENTOR June 25, 1963 s, MaccAFFRAY, JR 3,094,857

WARP KNITTED FILE FABRIC INVOLVING I ORIENTATION BY MODIFYING WARP Filed Feb. 26, 1960 12 Sheets-Sheet 'T INVENTOR June 25, 1963 5, aQ JR 3,094,857

WARP KNITTED FILE FABRIC INVOLVING ORIENTATION BY MODIFYING WARP Filed Feb. 26, 1960 12 Sheets-Sheet 8 June 25, 1963 5, aQ JR 3,094,857

WARP KNITTED FILE FABRIC. INVOLVING ORIENTATION BY MODIFYING WARP Filed Feb. 26, 1960 12 Sheets-Sheet 9 L) i l M)? INVENTOR MacCafl/ay, B

ATTORNEYS- June 25, 1963 5 MaocAFFRAY, JR 3,094,857

WARP KNITTED PILE FABRIC INVOLVING ORIENTATION BY MODIFYING WARP Filed Feb. 26, 1960 12 Sheets-Sheet 10 June 25, 1963 R. s. M cAFFRAY, JR 3,094,857

WARP KNITTED FILE FABRIC INVOLVING ORIENTATION BY MODIFYING WARP 12 Sheets-Sheet 11 Filed Feb. 26, 1960 R. s. M CAFFRAY, JR 3,094,857 WARP KNITTED FILE FABRIC INVOLVING ORIENTATION BY MODIFYING WARP June 25, 1963 12 Sheets-Sheet 12 Filed Feb. 26, 1960 Z0. )FZ/E INVENTOR 26x J2 Mawafi my, Jr.

United States Patent 3,094,857 WARP KNITTED PILE FABRIC INVOLVING ORIEN- TATION BY MODIFYING WARP Rex S. MacCalfray, Jr., Boiling Springs, Pa., assignor to C. H. Masland & Sons, Carlisle, Pa., a corporation of Pennsylvania Filed Feb. 26, 1960, Ser. No. 11,306 20 Claims. (Cl. 66-191) The present invention relates to warp knitted pile fabrics. The invention is applicable to pile fabrics generally but particularly to carpets, rugs, upholstery fabrics, decorative fabrics and the like.

This application is a continuation-in-part of my copending application Serial No. 856,263, filed November 30, 1959, for Warp Knitted Pile Fabric and Method Involving Orientation by Modifying Warp, now US. Patent 3,029,621. This application includes the fabric subject matter divided from application Serial No. 856,263.

A purpose of the invention is to control the orientation of the pile projections on a warp knitted pile fabric by means of two warp ends for each pile yarn end, one of which warp ends is formed into knitted stitches, and the other of which warp ends is laid into the knit-ted stitches.

A further purpose is to increase the tuft bind in warp knitted pile fabrics by use of two binding warps, one of which forms knitting stitches and the other of which is laid into the knitted stitches.

A further purpose is to reproduce a texture pattern in loop pile fabrics such as carpets or the like, especially level loop pile fabrics, by the use of a modifying warp end for each pile warp.

A further purpose is to produce a more glamorous and attractive pile fabric using a single guide bar for pile yarn, without the necessity of burying extra pile yarn or using extra laid-in pile yarn.

A further purpose is to avoid the alternate row effect, sometimes called the rowy effect, which is commonly as sociated with knitted pile fabrics.

A further purpose is to knit a pile fabric in which the legs of the pile projections are erected and held between stretches of two different warp yarn ends.

A further purpose is to first lock the forward or newly formed leg of each of the pile projections (loops) under the top stretches of knitting warp yarn stitches, and at the time of forming the pile projections, make this top stretch of knitting warp yarn pass around one side of the legs of the pile projection at the same time that an end of modifying warp yarn passes around the opposite side of the legs of the pile projection, the modifying warp yarn then being laid-in and bound under the same top stretch of knitting warp yarn.

A further purpose is first to hold the forward or newly formed leg of each one of the newly formed pile projections by means of a modifying warp end which passes around and over the base of each leg of the pile projection and which then is laid into the knitting warp stitch, the forward leg of the newly formed pile loop crossing over the newly formed warp chain stitch and being in a position so that it will be locked under the top stretch of the next warp chain stitch but not under the top stretch of the chain stitch of the present course.

A further purpose is to provide pile projections of pile yarn with legs which are laid into stitches of Warp knitting yarn, with a modifying warp yarn above the warp stitch binding point of the legs, the modifying warp yarn being laid into the same loops of warp knitting yarn, by shogging and moving opposite to the knitting yarn so that the modifying warp yarn ends will clamp the legs of the pile projections against the top stretch of the warp 3,094,857 Patented June 25, 1963 knitting yarn stitch, and will cause the legs of the pile projections to be erected into a vertical position or a position inclined from the vertical depending upon the tension in the modifying warp ends, at the same time orienting the pile projection in proportion to the tension applied to the modifying warp ends.

A further purpose is to produce a surface texture pattern in a pile fabric by selectively controlling the tension on the modifying warp ends for each individual end and for each stitch, the modifying warp ends pressing against the legs of the pile projections and moving in each stitch opposite to the knitting chain, and the modifying warp ends by tension clamping the legs of the pile projections between the top loops of the knitting stitches and the modifying warp ends. Thus under a high tension of the modifying warp ends one type of pile orientation will be obtained and under a lesser tension 3 different type of pile orientation will be obtained, due to the looser clamping action exerted on the legs of the pile projections against the top stretches of the knitting chain.

A further purpose is to produce a warp knitted pile fabric with a backing of sinuously laid-in backing yarn, warpwise lines of warp chain stitches locking the weftwise backing yarn into a flat fabric, face or pile yarn with legs of the pile projections held in the stitches of the knitting chain, and modifying warp yarn which is laid-in in the stitches of the knitting chain. The modifying warp yarn acts opposite to the knitting chain, so that the legs of the pile projections are clamped between the upper loops of the knitting chain and the modifying warp ends, causing the legs of the pile projections to be erected vertical in the fabric.

A further purpose is to prevent the: backing yarn from grinning or showing through on the face of the fabric, in areas of the carpet where the pile is low, or far apart, or where the pile projections are pulled down so that they are only flat in-laid stretches of yarn secured in the 1 knitted chains.

A further purpose is to utilize for the modifying warp face yarn, a quality of yarn which is suitable for face yarn but which is inferior to that used for the high pile projections, in respect particularly to resistance to wear,

and resiliency.

A further purpose is to make the modifying warp perform a dual purpose, that of modifying the orientation and particularly erecting the pile projections, and also contributing to the formation of the face of the carpet at areas between high pile projections.

Further purposes appear in the specification and in the claims.

In the drawings I have chosen to illustrate one only of the numerous embodiments in which the invention may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory operation and clear demonstration of the principles involved.

FIGURES 1 to 8, inclusive, are diagrammatic stepwise vertical sections showing the positions of the operating parts of the knitting machine in producing the fabric of the present invention, particularly directed to FIGURE 9, but serving as a basis for understanding the operations for producing all of the fabrics.

FIGURES 1a to 8a are enlarged and expanded diagrammatic plan views of the knitting according to FIGURES l to 8, to produce the fabric shown in FIGURE 9.

FIGURES 4b and 7b are enlarged expanded diagrammatic plan views of knitting steps which correspond to FIGURES 4a to 7a respectively, but: which illustrate the changes made in the method of FIGURES 1 to 8 and la to 8a in order to produce the fabric of FIGURE 13.

FIGURES 4c and 7c are enlarged expanded diagrammatic plan views corresponding to FIGURES 4a and 7a, but showing the modcations in the knitting steps of FIG- URES 1 to 8 and 1a to 8a which are employed in producing the fabric of FIGURE 14.

FIGURE lb is a view corresponding to FIGURE 11: but showing formation of out rather than uncut pile.

FIGURE 9 is a fragmentary expanded face of a fabric produced according to FIGURES 1 to 8 and la to 8a.

FIGURE 10 is an enlarged fragmentary section of FIG- URE 9 on .the line 10--10.

FIGURE 11 is an expanded plan view illustrating a cut pile fabric according to the invention. While the arrangement of the yarn corresponds to FIGURE 9, this figure is intended to indicate that cut pile can be used in any of the forms, following FIGURE 1b.

FIGURE 12 is an expanded plan view showing a modified form of the fabric of FIGURE 9, omitting the backing yarn.

FIGURE 13 is an enlarged expanded top plan view of a variation on the fabric of FIGURE 9, of the character produced in accordance with FIGURES 4c and 7c, omitting the backing wefts. In this form the pile projections have their legs bound in the same stitch and also in an adjoining stitch of the next chain.

FIGURE 14 is an enlarged expanded plan view of a modified fabric according to the invention, produced in accordance with FIGURES 4b and 7b, and omitting the backing wefts.

FIGURE 15 is an enlarged expanded plan view of a modified fabric according to the invention which is similar to that of FIGURE 14 except that the legs of the pile projections are bound in corresponding stitches of adjoining chains. The backing wefts are omitted.

FIGURE 16 is an enlarged expanded plan view of a modified fabric according to the invention which is similar to FIGURE 14 but has the modifying warp ends shogged across and engaged in corresponding stitches of adjoining chains. This omits backing yarn.

FIGURE 17 is a view similar to FIGURE 16 which illustrates a modification.

FIGURE 18 is a photographic face view of the fabric of FIGURE 9.

FIGURE 19 is a photographic face view of the fabric of FIGURE 14.

FIGURE 20 is a photographic face view of the fabric of FIGURE 17.

Describing in illustration but not in limitation and referring to the drawings:

The fabric and process of the present invention may be produced or carried out on a warp knitting machine of the Raschel type, of the character shown for example in my US. Patent No. 2,891,396, granted June 23, 1959, for Method of Producing a Fabric by Warp Knitting. It will be evident that from the standpoint of the present invention any suitable warp knitting machine of the general Raschel type is applicable, and can be used without any change in the machine except of course to provide suitable loop forming mechanism.

In warp knitted pile fabrics in the prior art it has been the practice in some cases to bind the legs of the pile projections into stitches of adjoining lines of warp chain stitches in the same course. In other prior art fabrics the legs have been bound in stitches of the same line of chain, or under stretches of binding weft, or in some cases under stretches of adjacent lines of chain warps and adjacent courses.

It will of course be evident that when a leg of a loop is bound into a knitting stitch, it is normally turned into a weftwise direction, and as the leg of the loop is bent upward to form the loop this bend from the weft-wise direction to the vertical tends to turn the loop, causing many types of yarns to form rows of loops in the same course all of which are oriented in a similar way and which vary only in alternate adjoining courses. Other types of binding of the loop with the leg resting flat on the fabric have a similar effect on the face of the fabric.

In some cases in warp knitted pile fabrics, this has been overcome by knitting the pile yarn into the needle stitch, and, since the legs of the pile projection are par-t of the stitch, the appearance of the face of the fabric is improved. This procedure is impossible, however, with very heavy pile yarns of the type commonly used in carpets, as the knitting needle would have to be so large that it could not be used with an ordinary carpet pitch or gage. Furthermore this procedure is very wasteful of pile yarn.

In the present invention the legs of the pile projections, which may be loops or tufts, are held between lJWO 0pposed warpwise stretches of yarn, and this forces the legs of the loops into a vertical position or a position close to the vertical. As a result a stiffer pile projection is formed, and yet, because of the inherent inflexibility of the warpwise stretches, the pile is more resilient, and has more resistance to crushing. Accordingly, the fabric is livelier and less likely to pack down.

In accordance with the invention it is possible to control the orientation of the pile projection by relatively adjusting the tension of one or both of the controlling warps without any other modifying means. One of the controlling warps is the warp which forms the chain of knitting stitches, and the other of the controlling warps is a modifying warp which is interlocked with the chain warp by laying-in.

Below the binding point the pile yarn may be laid-in into as many warpwise or Weftwise stitches as desired for the purpose of increasing the tuft bind, or to get distribution of the yarn ends in color patterns so that individual areas at the face of the pile will appear to be a particular color, as well known in the art. As this action take-s place low the binding point of the legs of the pile projections it has no effect on the orientation of the pile projections.

To get the best advantage from the present invention, it is not necessary to bury any pile yarn below the binding of the legs of the pile projection.

In the simplest form of the invention each chain warp yarn will be forming warpwise lines of alternate right and lefthand chain stitches which are engaged around bundles of weftwise stretches of backing yarn.

In front of the backing yarn guide bar there will be a pile yarn guide bar and immediately ahead of that there will be a modifying warp yarn guide bar, and then a knitting chain guide bar which will form knitting stitches.

In order to hold the fabric together it is only necessary that the knitting warp yarn form knitting stitches, but it will be evident that the modifying warp yarn may be similar to the knitting yarn, but it will in every case run in an opposite direction in each stitch to the direction of the warp knitting guide bar.

In each case when the warp knitting yarn end forms a righthand stitch around the needle hook, the modifying yarn end at the same Wale will be laid-in to the knitting yarn stitch in the opposite direction from the knitting stitch, but regardless of the type of knitting stitch used, the modifying Warp yarn will be laid-in so that the base legs of the pile loops will be in between the top stretch of the knitting yarn stitch and the warpwisestretch of the warp modifying yarn.

The pile yarn will form pile projections on books or socalled plush points set to the same gage as the needles, and the new or forward legs of the pile projections, extending back through the knitting yarn and modifying warp yarn, will be locked between the knitting yarn and the modifying warp yarn as the sitich is made and locked.

It will be evident of course that the invention can be embodied in various different forms as later explained.

In one preferable form of the invention, the fabric is particularly well adapted to produce pile carpet with high and low loops of face yarn forming a surface pattern. This technique is responsible for the sharp definition of high and low pattern pile projections which is obtained, as contrasted with the prior art when there is often gradual demarcation between high and low pile.

In the above discussion it has been assumed that the modifying warp performs its most important function by changing the orientation of the pile, and therefore the character and construction of the modifying warp need not be like face yarn or pile yarn. In many cases, however, it will be advantageous to employ modifying warp yarn which itself is face yarn, suited to form part of the face of the carpet or other fabric, and particularly to appear at the face in wells of the pile or in background areas which are interspersed among pile areas. In this instance the modifying warp yarn performs a dual function, since it modifies the orientation of the pile, but also for-ms in-lays which produce coverage for the back of the fabric in the wells.

Before describing the somewhat more complicated embodiments, I will describe a relatively simpler form of the invention.

In this embodiment of the invention the forward leg of each loop as formed is bound only under the stretch of the modifying warp yarn which passes around the base of the pile projection and then into the knitting stitch. At this point in the knitting process the size of the pile loop can be controlled by tension on the pile yarn because the pile loop is very loosely bound. The forward leg of this loop passes across above the top binding stretch of the knitting warp yarn, and as the next loop is formed and bound in turn by the second warp end, the stitch Will not only bind the second warp end in this following stitch but will also bind in what was formerly the leading leg of the previous loop.

It will be evident however, that when level pile is formed, it is more advantageous to form the loop of pile yarn in such a way that the leading leg of the loop will be knitted into the existing and forming knitting stitch.

First considering the form of the invention as embodied in FIGURES 1 to 8, 1a to 8a, 9 and 10, the warp knitting machine is suitably a double needle bar Raschel type, one needle bar mounting supports for a series of latch needles 21, as well known, which extend vertically and are guided by a trick plate 22, which is tapered and extends generally vertically, the fabric being taken off at one side and the needles being guided at the other side.

The latch needles, as well known, have hooked ends 23 at the top directed away from the trick plate, and latches 24 pivoted at 25, and in one position closing against the book ends.

The other needle bar in the device of the invention is equipped with a plush point mounting 26 which carries generally vertically extending plush points 27. The plush points can be cutting or non-cutting as desired, and as later explained in more detail, but FIGURES 1 to 8 show non-cutting plush points which at the upper ends toward the trick plate have recesses 28.

A sinker comb 30, as well known, is mounted on sinker supports 31 and moves across the top of the trick plate. A latch wire 32 extends across the back of the machine.

A swing bar acros the machine supports a series of separately shoggable guide bars of well known character, comprising a knitting yarn guide bar 33 having eyes which guide knitting yarn 34, a modifying yarn guide bar 35 having eyes which guide modifying yarn ends 36, a pile yarn guide bar 37 having eyes which guide pile yarn ends 38, and a backing yarn guide bar 40' having eyes which guide backing yarn ends 41. The various ends are suitably placed at each needle position in the preferred embodiment.

Considering now particularly FIGURES 1 to 8 and la to 811, in FIGURES 1 and la which correspond to zero or 360 in the cycle, the first step is being taken after completion of the last stitch, the needles 21 and the plush points 27 are down or retracted, the sinker comb 30 is advanced or forward, and the swing bar with the various guide bars is in mid-position and moving back. At this position the backing yarn guide bar shogs to lay-in stretches 42 of backing yarn.

FIGURES 2 and 2a correspond to of advance in the cycle. The position of the needles and of the singers is the same as in FIGURE 1. The guide bars are all the way back, out of line with the needles and the plush points, and the plush points have just completed their forward or upward motion. If the plush points are cutting as later explained (FIGURE lb) they will at this point cut the previous loops.

Backing yarn guide bar continues to shog in the same direction forming backing yarn stretches 43.

FIGURES 3 and3a correspond to the position at 90 in the cycle. The swing bar and the guide bars with it move to the front past the raised plush points and pile yarn guide bar 37 now shogs so that in the next succeeding step pile loops will be formed around the plush points as well known in the art. The formation of such loops is shown at 44 in FIGURE 3a.

At 150 in the cycle, as shown in FIGURES 4 and 4a, the swing bar ha moved back, carrying with it the guide bars, while the position of all of the other elements remains the same. Modifying yarn guide bar 35 now shogs to form stretches 45 over the new legs of loops 46 of pile yarn 38.

The position at FIGURES 5' and 541', corresponding to 210 in the cycle, corresponds to the completion of all shogging except for the knitting yarn. The pile yarn and knitting yarn guide bars have moved forward past the plush points. Depending on the shogging positions, the pile yarn has formed loops 47 around the plush points. The needles 21 have advanced or raised and the latches 24 of the needles have been opened by the previous knitting stitch as shown at 48 and as well known.

The position of FIGURES 6 and 6a corresponds to 270 in the cycle. All guide bars have moved back of the plush points and the needles, and the new stitch is ready to be formed when it enters the hook of the needles in the next step. The pile yarn ends are now arranged in more completely formed loops 47 around the plush points and the backing yarn is now laid-in in stretches 50 in the stitches, while the knitting yarn guide bar 33' is now shogging to place the knitting yarn in the hooks of the needles above the latches. This forms loops 5-1 of knitting yarn.

In FIGURES 7 and 7a at 300 in the cycle, the guide bars are moving to the front and are midway in their swing. The sinker comb 30, which has been in position across the fell and across the end of the trick plate and among the plush points, is now retacted to clear the ends of the needles, and the needles are beginning to retract and the latch is closed by the previous stitch, and the plush points are retracting. The effect therefore is to bind the stretches 52 of modifying warp yarn 36 and bind the forward legs of the pile projections 47, with the stretches of knitting yarn and of modifying warp yarn on opposite sides of the legs of the pile projections.

FIGURES 8 and 8a, corresponding to 330 in the cycle, show the guide bars moving to the front and midway in their swing. The sinker comb 30 is fully retracted and is now about to advance again to the position of FIGURE 1. The needles have fully retracted.

By reference to FIGURES 9' and 10, it will be evident that the completed fabric comprises a series of warpwise chains of successive righthand and lefthand stitches 53, each of which has bottom stretches 54 and a top stretch 55. Engaged in stitches between the top and bottom stretches are bundles 56 of weftwise stretches of backing yarn 41. The pile projections 47 have legs '57 and 58 which are bound beneath the top stretches of successive knitting stitches of the same knitting chain. On the opposite side of each pile projection from the top stretch of each stitch is a stretch 60 of modifying warp yarn 36 which is running warpwise engaged beneath the top stretch of each stitch and extending sinuously. The stretches 60 of modifying warp yarn 36 are always op- 7 posite to the direction of formation of the stitch in any course.

Thus each modifying warp end 36, in this form remains in one line of chain stitches. The tension of the modifying Warp end with respect to the tension of the chain is important and will suitably be controlled and in some cases modulated in the present invention. The tension of the knitting chain should always be higher than that of the modifying warp end.

A typical knitting yarn tension is likely to be of the order of two pounds per end and as compared with this the modifying yarn tension is likely to be of the order of from three to six ounces.

It will be evident that the tension of the modifying warp end can be controlled from stitch to stitch using a paternt control mechanism as shown in the following US. patents: Rex S. MacCatfray, In, Patents Nos. 2,784,689 and 2,811,244; Frank W. E. Hoeselbarth Patent No. 2,842,259; C. H. Masland, 2nd, Patents Nos. 2,866,424 and 2,880,684.

It will be noted that as each stitch of knitting warp yarn is formed, it also binds in a stretch of modifying warp yarn and binds the forward leg of the pile projection. As the stitch is locked the pile loop legs 57 and 58 are locked. These locking points are formed by the pressure of the modifying warp end stretch 60. The effect is to erect the pile projections (the plan views show it lying down according to a convention well known in the art to permit seeing it as a pile loop, but actually the pile projection extends upwardly). In the second place there are additional binding points established for the pile projection, which increase the tuft bind.

in FIGURE the grip of the modifying warp end 36 on the leg 58 of the pile projection 47 is clearly shown at 61.

It will be evident that the invention is applicable to cut pile fabrics as well as loop pile fabricsand in FIGURE 11 I show out pile projections 47' produced by the technique of the present invention through the use of a cutting plush point 27' as described in detail in my Patent No. 2,891,396 above referred to, and shown in FIGURE 1b.

For most purposes the tuft bind of FIGURE 9 or FIG- URE 14 is adequate, but when the pile yarn shogs from one chain to another as in FIGURE 15, greater tuft bind is also gained by the extra lay-in of the leg of the pile projection between the two chains.

In some cases it is preferable to modify the form of FIGURES 1 to 8, 1a to 8a, 9 and 10 by binding the legs of the pile projections in adjoining stitches of the same chain and also in adjoining stitches of adjoining chains, while obtaining the same orienting effect by the modifying warp end as already described. Thus in FIGURE 12 the pile loop legs 57 and 58 each have stretches 67 and 68 which are shogged across to the next knitting chain and bound-in in the corresponding stitches of the next chain, so that the particular pile warp end, instead of remaining always in the same wafle, forms pile alternately in adjoining wales.

In some cases it is preferable to bind the legs of the pile projection 47 in the same stitch. This is shown in FIG- URE 13, Where the legs 57 and 58 of the pile projections 47 are bound in the same knitting stitch, and also con nected by stretches 67 and 68 which are shogged across to the next knitting chain and are bound in adjoining stitches in the next knitting chain. In this case each pile projection is fully formed and locked with both legs in the same stitch instead of having its legs split and locked in successive courses.

In FIGURE 13 the effect of the modifying warp end in erecting the loop and meeting the tuft bind is the same as that described in the previous form.

The technique of producing the fabric of FIGURE 13 is illustrated by FIGURES 4b and 7b.

In FIGURE 4b, corresponding to FIGURE 4a, the modifying yarn ends 36 are shogged to form loops 70 over 8 the new legs of the pile projections as previously described, and it will be evident that both legs of the pile loop 47 are engaged in loop '51 of knitting yarn.

In FIGURE 7b, it will be evident that as shown previously in FIGURE 7a, the pile loop 47 is engaged in the stitch and in this case the nearly completed stitch has secured both ends of the pile loop. The stretch of modifying warp end is shown at 71.

FIGURE 14 shows a further embodiment of the invention, which is particularly adapted for forming high and low pile by control of the feed of the pile yarn so as to produce very high and very low loops in succeeding courses of the same pile yarn ends.

As each succeeding warp stitch is made by the needles, loops of pile yarn form around the plush points, and the leading or forward leg of each pile projection is crossed and held by the modifying warp yarn at 72 as shown in FIGURE 14. The modifying warp yarn as in the previous forms always runs opposite to the looping motion of the knitting yarn stitch. As the knitting stitch is formed, the knitting stitch does not catch the forward leg of the pile loop at the time of loop formation, but instead merely locks the modifying warp ends which are holding the forward legs of the pile loops 47 at 72. The knitting yarn stitch, however, does knit in the last leg of the loop which was the forward leg of the previous loop as shown at 73 in FIGURE 14, because the pile loop in forming crosses in front of the knitting yarn.

Thus it will be evident that the modifying warp yarn passes around the forward leg of the pile projection and then under the top stretch of the warp knitting yarn in the same course, the forward leg of the pile projection avoiding the path of the warp knitting stitch of the same course, and the forward leg of the previous pile projection is lapped under the top stretch of the warp knitting yarn of the next stitch and course, it not being lapped under the knitting yam of the previous course.

Thus it is that each pile loop as it formed is bound only by the relatively loose stretch 60 of the modifying warp yarn end, and the pile loop 47 in consequence is subject to being pulled back until it is nonexistent or just a flat end in the surface, or it may be allowed to remain at its full height, or it may be pulled down to any intermediate height, as suggested by the dotted line 74 in FIG- URE 14. This is accomplished by a pattern control of the character of the MacCaffray patents and Masland patents aforesaid, which control each individual pile yarn end as it is fed during each stitch. The pile yarn loop remains at this height locked only by the modifying warp and until the next succeeding knitting stitch is formed, at which time the pile loop will be locked completely by the knitting stitch and will almost appear as though it had been formed by the original double locking method of FIGURE 9.

FIGURE 40 at in the cycle illustrates the formation of the loop 47 which is locked in the stitch at one end and is locked at the other end only at 72 by the modifying warp end 36, and FIGURE 70 at 300 in the cycle shows that this condition remains even when the knitting yarn stitch is nearly completed at 51. FIGURES 4c and 7c otherwise correspond to FIGURES 4a and 7a.

It will be evident that if desired the control of the modulation of the tension on the modifying warp ends as well as the modulation of the tension, on the pile warp ends may be employed in FIGURE 14, in which case there will be differences in orientation as well as differences in height of the different pile projections.

FIGURE 15 shows a fabric which in other respects is similar to that of FIGURE 14 with the same locking of the pile projection as that of FIGURE 14, namely, by the modfying warp stretch 60 as well as by the succeeding knitting stitch. In this case, however, there are stretches 67 of pile yarn ends which extend across and provide locking of the legs of the pile projection also in the corresponding stitch of the next knitting chain 53. In this case the pile projections of any particular yarn end will not come up in the same knitting chain on two succeeding courses.

FIGURE 16 illustrates another embodiment of the invention which in this case is similar to that of FIGURE 14, except that between the stretches 60 of the modifying yarn ends they shog across weftwise at 75 to the next knitting chain and are engaged in the corresponding stitches of the same course. This provides a somewhat different form of double bind, but the erection of the pile projections is similar to that in the other forms of the invention.

In FIGURE 17 I illustrate a construction in which the modifying warps function as face yarn in wells or the like. The backing lay-in goes across three or more wales as in other forms. In this view there are parallel lines of knitted crochet stitches 76, dual purpose modifying and face warp yarn ends 77, and pile warp ends 78 each sup plied by a different guide bar of the warp knitting machine as well known in the art. The backing yarn which extends sinuously back and forth between the lines'of knitting chains as illustrated for example in FIGURES 9, 10 and 1'1, is omitted in FIGURE 17 so as not to cause confusion in reading the view.

In this instance the modifying in-laid warp yarn 77 has the relatively bulky character and wear resistance which are characteristic of face yarn, and is intended to be seen and felt as part of the face of the finished fabric.

The pile yarn 78 in this instance forms high loops 80 and low loops 81, in view of the operation of any suitable pattern control that is capable of varying the tension on individual pile warp ends which are fed to individual stitches, a suitable example being C. H. Masland, 2nd, US. Patent No. 2,880,684, granted April 7, 1959, for Formation of High and Low Pile by Needling; C. H. Masland, 2nd, US. Patent No. 2,866,424, granted December 30, 1958, for Control of Pile Height in Needling; my US. Patent No. 2,811,244, granted October 29, 1957, for Needling Pile Fabric; and my US. Patent No. 2,784,689, granted March 12, 1957, for Formation of High and Low Loops by Needling.

The low pile loops 81 may, if desired, be reduced to flat stretches 82 of pile yarn, which are almost completely buried beneath the modifying warp yarn 77. There are therefore three conditions of pile yarn, that is, high pile loops, low pile loops, and absence of pile loops, as shown.

Where the pile yarn forms high pile loops 80, this will conceal the modifying warp yarn 77 and produce a face in the area of the high pile loops which is entirely formed by pile yarn 78. In such areas the modifying warp 77 functions purely as a modifying warp and holds the pile projection in position and erect as shown at 83, until the last for-med leg of the pile loop is knitted into the following knitted stitch at 84.

If the pile projections are low as shown at 81, both the pile yarn 78 and the modifying warp yarn 77 will show at the face, and the face of the fabric will be a blend of the two yarns in proportion to the size of the loop.

n the other hand at 82 where the pile yarn is substantially completely buried, there will be no loop of pile yarn 78, and modifying warp yarn 77 will form the face of the fabric. Therefore it will be evident that suitable coloring and appearance of the modifying warp yarn will be desirable to form the correct pattern in these areas where the modifying warp yarn forms the face of the fabric, as in wells and background.

FIGURE 20 illustrates the face of the fabric according to the invention, showing a large number of wells in which the modifying warp forms warp stretches which cover the face.

It will be evident that the principles of the invention can also be applied to a fabric according to my copending application Serial No. 837,728, filed September 2, 1959, now abandoned, for Warp Knitting With Pile Contributing to Lay-In Weft Bind, in which the laid-in weft forming warp yarn makes not only a lay-in but also forms 10 a pile loop and is therefore similar in some of its characteristics to the warp modifying lay-in in this case. It will therefore be evident that the modify-ing warp in accordance with similar principles can be used to form pile loops in the present invention.

It will be evident that according to the present invention the pile loops are formed and held by an in-laid stretch of modifying warp yarn and the base of the leg of the pile loop is not locked and stabilized until after the succeeding loop has been fully formed and the succeeding stitch locked.

The usual knitted stitches as referred to in the specification are in some cases described in the claims as crochet stitches as well known in the art.

In view of my invention and disclosure, variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefiits of my invention without copying the fabric shown, and I, therefore, claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention what I claim as new and desire to secure by Letters Patent is:

l. A warp knitted pile fabric comprising sinuously laid-in backing yarn forming bundles, warpwise rows of chain stitches binding together the backing yarn bundles, pile yarn forming pile projections the legs of which are bound into the warpwise rows of chain stitches, and modifying warp yarn also bound by inlay into the chain stitches and passing around the legs of each pile projection on the side opposite to the top stretch of the associated warpwise chain stitch, thus binding the legs of the pile projection between the said top stretch and the said modifying warp yarn.

2. A warp knitted pile fabric having knitted chains of successive right and lefthand crochetstitches extending warpwise, backing yarn extending weftwise and engaged in the knit-ted stitches, pile yarn forming pile projections and extending warpwise and with base legs engaged in the knitted stitches, and modifying warp yarn wrapped around the legs of each pile projection on the side opposite to the top stretch of the associated warp knitted stitch, and bound by inlay in the knitted stitch, the modifying warp yarn aiding in binding and also in erecting the pile projections.

3. A pile fabric of claim 1 in which the pile projections are uncut pile loops.

14. A pile fabric of claim 1, in which the pile projections are cut pile tufts.

5. A pile fabric of claim 1, in which the opposite legs of the pile projections are bound in successive stitches of the same chain.

6. A pile fabric of claim 1, in which the pile yarn extends weftwise between chains, and the opposite legs of the pile projections are bound in successive stitches of the same chain.

7. A pile fabric of claim 6, in which the opposite legs of the pile projections are bound both in adjoining stitches of the same chain and corresponding stitches of adjoining chains.

-8. A pile fabric of claim 1, in which the legs of the pile projections are bound in the same stitch of the chain.

9. A pile fabric of claim 8, in which the opposite legs of the pile projections are also bound in successive stitches of an adjoining chain.

10. A pile fabric of claim 1, in which the modifying warp yarn passes around the forward leg of the pile projection and then under the top stretch of the warp knitting yarn in the same course, the forward leg of the pile projection avoiding the path of the warp knitting stitch of the same course, and the forward leg of the previous pile projection being lapped under the top stretch of the Warp knitting yarn of the next stitch and course, it not being lapped under the knitting yarn in the previous course.

11. A pile fabric of claim 10, having different pile projections of different heights.

12. A pile fabric of claim 1, in which one leg of the pile projections is bound in a particular stitch of the knitting chains and the opposite leg of the pile projections is bound by the modifying warp crossing said opposite leg and then the said opposite leg of the pile projection is bound only by the modifying warp crossing until the next stitch of the same warp knitted chain.

13. A pile fabric of claim 12, in which the leg of the pile projection is also bound in the corresponding stitch in an adjoining knitted chain.

14. A pile fabric of claim 12, in which the modifying warp yarn follows a sinuous course and is engaged in the stitches of adjoining knitted chains.

15. A pile fabric of claim 1, in which the modifying Warp yarn follows a sinuous course and is engaged in stitches of at least two adjoining knitted chains.

16. A pile fabric of claim 1, in which the pile projections are of variant height throughout the fabric.

17. A warp knitted pile fabric, comprising walewise extending parallel chains of knitted crochet stitches, inlaid backing weft yarn ends extending walewise, each undulating sinuously across and bound into the stitches in at least three of the knitted chains, pile warp yarn forming pile projections at intervals, the pile projections alternating in adjoining walewise rows and with the base legs of the pile projections bound by inlay into the knitted stitches, modifying face warp yarn free from pile projections undulating sinuously across lines of knitted chains and bound into the stitches of the chains, the modifying face warp yarn in its undulating sinuous path wrapping around base legs of the pile projections, bound by inlay in the knitted stitches, and modifying the orientation of the pile projections so that they are forced to assume a more nearly vertical position in the fabric, the face of the fabric including areas in which the pile projections form the face and conceal the laid-in modifying face warp yarn, and areas in which the modifying face warp yarn forms the face of the fabric and .is visible at the face of the fabric.

'18. A pile fabric of claim 17, having high pile projec tions which form the face of the "fabric in certain areas and conceal the modifying face warp yarn and having lower pile projections which in other areas allow the modifying face warp yarn to be visible between lower pile projections of the pile warp.

19. A pile fabric of claim 18, in which certain areas are composed entirely of modifying face warp yarn at the face of the fabric, there being in such areas loops of the pile Warp which are pulled down to the back where they form mere stretches of yarn under the modifying face warp yarn.

.20. A warp knitted pile fabric, comprising parallel chains of knitted crochet stitches extending warpwise, the successive stitches being respectively lefthand and righthand, backing yarn extending sinuously weftwise and laid in the stitches of the knitted chain, pile yarn extending warpwise, rising in pile projections and having legs of each pile projection boundxin the stitches of the knitted chains, and modifying warp yarn extending sinuously warpwise and also inlaid and bound .in the stitches of the knitted crochet stitches, at each crochet stitch where at least one base leg of each pile projection extends from the inlay in the stitch, the said base legs also extending between the top single stretch of yarn in the crochet stitch and the warpwise stretch of the modifying warp yarn.

References Cited in the file of this patent UNITED STATES PATENTS 1,475,325 Springthorpe Nov. 27, 1923 2,396,525 Newman Mar. 12, 1946 2,531,718 =Rice Nov. 28, 1950 

1. A WRAP KNITTED PILE FABRIC COMPRISING SINUOUSLY LAID-IN BACKING YARN FORMING BUNDLES, WARPWISE ROWS OF CHAIN STITCHES BINDING TOGETHER THE BACKING YARN BUNDLES, PILE YARN FORMING PILE PROJECTIONS THE LEGS OF WHICH ARE BOUND INTO THE WARPWISE ROWS OF CHAIN STITCHES, AND MODIFYING WARP YARN ALSO BOUND BY INLAY INTO THE CHAIN STITCHES AND PASSING AROUND THE LEGS OF EACH PILE PROJECTION ON THE SIDE OPPOSITE TO THE TOP STRETCH OF THE ASSOCIATED WARPWISE CHAIN STITCH, THUS BINDING THE LEGS OF THE PILE PROJECTION BETWEEN THE SAID TOP STRETCH AND THE SAID MODIFYING WARP YARN. 